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Cr-FREE METALLIC-CERAMIC
COATINGS
ASETS Defense 2014 Fort Myer, VA,
November 18-20, 2014
Bruce McMordie Coatings for Industry
319 Township Line Road Souderton, PA 18756
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1. REPORT DATE NOV 2014 2. REPORT TYPE
3. DATES COVERED 00-00-2014 to 00-00-2014
4. TITLE AND SUBTITLE Cr-Free Metallic-Ceramic Coatings
5a. CONTRACT NUMBER
5b. GRANT NUMBER
5c. PROGRAM ELEMENT NUMBER
6. AUTHOR(S) 5d. PROJECT NUMBER
5e. TASK NUMBER
5f. WORK UNIT NUMBER
7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) Coatings for Industry,319 Township Line Road,Souderton,PA,18756
8. PERFORMING ORGANIZATIONREPORT NUMBER
9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSOR/MONITOR’S ACRONYM(S)
11. SPONSOR/MONITOR’S REPORT NUMBER(S)
12. DISTRIBUTION/AVAILABILITY STATEMENT Approved for public release; distribution unlimited
13. SUPPLEMENTARY NOTES ASETSDefense 2014: Sustainable Surface Engineering for Aerospace and Defense, 18-20 Nov 2014, FortMyer, VA.
14. ABSTRACT
15. SUBJECT TERMS
16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF ABSTRACT Same as
Report (SAR)
18. NUMBEROF PAGES
26
19a. NAME OFRESPONSIBLE PERSON
a. REPORT unclassified
b. ABSTRACT unclassified
c. THIS PAGE unclassified
Standard Form 298 (Rev. 8-98) Prescribed by ANSI Std Z39-18
Aluminum-Ceramic Coatings on Gas Turbine Compressors
Essential to Life of Steel Parts • cases, blades, vanes, shafts
Various Coatings and Systems • Alseal 518 & 519 • SermeTel W & 962 • IP9183 & 9442 • Ceral 114 & 34 • SermeTel 5380DP
Nov. 2014 ASETSDefense 2014, Fort Myer, VA 2
Aluminum-Ceramic Coatings
Slurries of Al in chromic & phosphoric acids Spray and Bake.
• Chemically bonds to steel.
Very Durable • Stable to more than 1000F (540C). • Resists salt corrosion, even when heated. • Unaffected by water, fuel, oils. • Tightly Adherent. Resists chipping.
Nov. 2014 ASETSDefense 2014, Fort Myer, VA 3
Aluminum-Ceramic Coatings Introduced in 1960’s Technology Evolved
• Polished (blades & vanes) – 1975 • Corrosion Resistant Sealer – 1978 • Low Temp. Cure – 1980 • Polished & Sealed – 1980 • Dense & Smooth - 1987
Now Widely Specified . . . • PWA, CPW, GEAE, GE Energy, Siemens, others
• Materials - PWA 595, GE A50TF1, CPW 88 and more • Processes – PWA 110, GE F50TF62, and more
. . . And Used • JT3D, JT8D, CF6-, T700, Allison 250, PT6-, etc.
Nov. 2014 ASM/TSS Aerospace Ctgs. Conf. & Expo. 4
•
Al-Chromate/Phosphate Slurries Contain Hexavalent
Chromium
PEL = 5 micrograms/m3
No Cr+6 Remains After Cure
Source of Cr+6 in Depots
Oct. 2014 ASETSDefense 2014, Fort Myer, VA 5
•
PEWG Ultimate Green Engine
(circa 2006)
Effort to Remove Cr+6 from Repair Depots
PEWG AFRL-ML-WP-TR-2007-4069 Compared . . .
• Aluminum-Inorganic Silicate Coatings For Industry (CFI)
• Al-Chromate/Phosphate (Std.) Sermatech (now Praxair/PST)
Nov. 2014 ASETSDefense 2014, Fort Myer, VA 7
Aluminum-Silicate Comparable to
Aluminum-Chromate/Phosphate Humidity Resistance Galvanic Corrosion Resistance
Nov. 2014 ASETSDefense 2014, Fort Myer, VA 8
Source: AFRL-ML-WP-TR-2007-4069, Sept. 2006
• >3000 hrs., scribed & unscribed, ASTM B117 salt fog.
no rust, pitting, or undercutting at scribe
(Al-silicate on 1010 carbon steel,
<10 ohms resistance as burnished)
Aluminum-Silicate Comparable to
Aluminum-Chromate/Phosphate Humidity Resistance, Galvanic Corrosion Resistance
Heat/Salt Resistance
• Nov. 2014 ASETSDefense 2014, Fort Myer, VA 9
Source: AFRL-ML-WP-TR-2007-4069, Sept. 2006
• Ten test cycles • One cycle = 6 hrs. @ 875F / 16 hrs. salt fog
1010 carbon steel
<10 ohms resistance as
burnished
Aluminum-Silicate Comparable to
Aluminum-Chromate/Phosphate Humidity, Galvanic Corrosion, Heat/Salt Resistance
Adhesion & Compatibility
Nov. 2014 ASETSDefense 2014, Fort Myer, VA 10
• 90 degree bend around 8X dia. mandrel
2.16 mils
1/8" 1/8"
1010 carbon steel, two coats, each cured 30 min. at 650F
1/8"
Detail of coating along edges
Aluminum-Silicate Comparable to
Aluminum-Chromate/Phosphate
Humidity Resistance Galvanic Corrosion Resistance Heat/Salt resistance Adhesion/Substrate Compatibility
Nov. 2014 ASETSDefense 2014, Fort Myer, VA 11
Source: AFRL-ML-WP-TR-2007-4069, Sept. 2006
Sealed Aluminum-Silicate Not Comparable to Sealed
Aluminum-Chromate/Phosphate in PEWG Evaluation
Corrosion Resistance – No Post Treat Abrasion Resistance Hot Oil, Water Resistance - Sealer
Oct. 2014 ASETSDefense 2014, Fort Myer, VA 12
Source: AFRL-ML-WP-TR-2007-4069, Sept. 2006
• Falling Sand Test of Al-Silicate Basecoat >100 L sand per 1 mil (25 µm) per ASTM D968
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
0 100 200 300
Mils
Los
t
Liters of Sand
Al-silicate (no topcoat)
Al-Cr2O7/PO4 Sealed-silicate (PEWG)
MIL-C-81751
Nov. 2014 ASETSDefense 2014, Fort Myer, VA 13
Abrasion Resistance of Aluminum-Silicate Without Sealer
Comparable to Al-Chromate/Phosphate
Inorganic Phosphate Sealer for Aluminum-Silicate
Unaffected by Hot Fluids
Nov. 2014 ASETSDefense 2014, Fort Myer, VA 14
Al-silicate with 1st
generation sealer in
PWEG test
Same Al-silicate
with new sealer in same test
Stable in Hot Water • After 24 hrs. at 120F (49C) in distilled water
Inorganic Phosphate Sealer for Aluminum-Silicate
Unaffected by Hot Fluids
Nov. 2014 ASETSDefense 2014, Fort Myer, VA 15
Stable in Hot Oil • After 8 hrs. at 400F (204C) in MIL-L-7808 Oil
Al-silicate with 1st
generation sealer in
PWEG test
Same Al-silicate
with new sealer in same test
Salt Spray Corrosion (ASTM B117) • 2000 hrs. scribed and unscribed.
2000 hrs. B117
no rust, pitting, or undercutting
at scribe
(Coating on plain carbon steel)
Nov. 2014 ASETSDefense 2014, Fort Myer, VA 16
Sealed Aluminum-Silicate Comparable to Sealed
Aluminum-Chromate/Phosphate
Heat Cycle Salt Spray Corrosion
• 10 cycles 6hrs. @ 750F (399C)/16hrs. 5% salt fog
Nov. 2014 ASETSDefense 2014, Fort Myer, VA 17
Al-Cr/PO4 sealed with
Cr/PO4
(4130 alloy steel)
Al-silicate with
improved sealer
(4130 alloy steel)
Sealed Aluminum-Silicate Comparable to Sealed
Aluminum-Chromate/Phosphate
PEWG Update
Nov. 2014 ASETSDefense 2014, Fort Myer, VA 18
With Inorganic Phosphate Sealer, Al-Silicate Comparable to
Sealed Al-Chromate/Phosphate Humidity Resistance Galvanic Corrosion Resistance Heat/Salt Resistance Adhesion/Substrate Compatibility Abrasion Resistance Hot Oil, Water Resistance - Sealer Corrosion Resistance - No Post Treat
Galvanic Corrosion Resistance • Pyrowear 53 HSLA steel, with & without sealer
1000 hrs., 5% neutral salt fog, B117
Nov. 2014 ASETSDefense 2014, Fort Myer, VA 19
Sealed, Cured 1 hour
at 425F
Sealed and unsealed (center),
Cured 4 hours at 425F
Beyond PEWG - Aluminum-Silicate on HSLA Steel
Single component (One Bottle) Easy to Apply
• Air-atomizing spray guns • No special spray booths
(humidity control a good idea) • Possible “drop-in”
Compatible with many substrates • Carbon & HSLA steels • Stainless steels • Nickel-base alloys • Titanium • Aluminum
Water clean-up with no hazardous waste
Nov. 2014 ASETSDefense 2014, Fort Myer, VA 20
Aluminum-Silicate Handles Like
Aluminum-Chromate/Phosphate
Degrease substrate Blast with 120 mesh Al2O3 grit Apply Al-silicate
• HVLP air-atomizing spray equipment
Air dry 15 minutes Heat dry 15 minutes at 175°F Cure 30 minutes at 650°F Apply a second coat or post-treat as desired
• Can defer cure of 1st coat until 2nd is applied.
Nov. 2014 ASETSDefense 2014, Fort Myer, VA 21
Aluminum-Silicate Is Processed Like
Aluminum-Chromate/Phosphate
Hazards of Inorganic Aluminum
Metallic-Ceramics Al-Cr2O7/PO4
• Zero VOC’s. • 13.0 wt. % inorganic
phosphates • 3.3 wt. % Cr+6
(hexavalent chromium) before curing.
Al-silicate • Zero VOC’s • No hazardous mat’ls
• No carcinogens
Nov. 2014 ASETSDefense 2014, Fort Myer, VA 22
Alseal® 5K Al-Silicate
Nov. 2014 ASETSDefense 2014, Fort Myer, VA 23
Alseal 5K†‡+5KT8 on PWA GG-4 compressor disk Courtesy, Blastech Overhaul & Repair, Bloomfield, CT
Polished Alseal 5K† on V8 exhaust header
Courtesy, Maryland Performance Coatings, Sykesville, MD
† US Pat. App. 2006/0166014 A1
First Generation Open-Market
Al-Silicate Coating
Alseal® 5KT8 Sealer
‡ PWA 36595
Nov. 2014 ASETSDefense 2014, Fort Myer, VA 24
Specified by Pratt & Whitney • PWA 36595 Rev. B
• Issued July 2007, Revised Nov. 2010 • Used on PW4000 shafts
In Test at Other OEMs • GE Power • Rolls-Royce North America • GEAE • SNECMA
Alseal® 5K Aluminum-Silicate
Al-Silicate Coating System Now Available That Can
Eliminate Hazards of Carcinogenic Cr+6
in Al-Chromate/Phosphate Compressor Coatings.
Nov. 2014 25 ASETSDefense 2014, Fort Myer, VA
Further Develop Capabilities • Sealers? • Low Temperature Cure? • Smooth Finishes? • Process Variables? • Limits?
Discover New Fundamentals • 1 to 1 Correlation Not Guaranteed • Ex. - Replacing Plating with Paint
• Different thickness constraints • Blueprint Changes
Produce Documentation • Process Instructions • Controls • Prints & Drawings
Nov. 2014 26
Challenges
ASETSDefense 2014, Fort Myer, VA
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